Computer hinge with hollow and partially annular clutch

ABSTRACT

A hinge assembly having a hollow and partially annular clutch is arranged to pivotally couple a portable computer base portion to a portable computer lid portion. The hinge assembly includes at least an elongated, hollow and partially open cylindrical portion that includes a partially annular outer region and a central bore region, the central bore region suitably arranged to provide support for electrical conductors between the base and lid portions. The hinge assembly also includes a plurality of fastening components that couple the hollow clutch to the base portion and the lid portion of the portable computer, with at least one of the fastening regions being integrally formed with the hollow and partially open cylindrical portion such that space, size and part count are minimized.

CROSS REFERENCE OF RELATED APPLICATION

This patent application claims priority to commonly owned and co-pending U.S. Provisional Patent Application No. 61/505,952, filed Jul. 8, 2011 by Degner et al., entitled “COMPUTER HINGE WITH HOLLOW AND PARTIALLY ANNULAR CLUTCH,” which is incorporated herein by reference in its entirety and for all purposes.

TECHNICAL FIELD

The present invention relates generally to manufacture of portable computing devices, and more particularly to the formation of advanced hinge assemblies for coupling major components

BACKGROUND

Portable computing devices having movable parts generally require hinge mechanisms that assist the movement of one major component relative to another. For example, a laptop computer or clamshell type cellular telephone can be formed of a lower base component that is movably coupled to an upper display component. The lower base unit or assembly can typically include items such as a keyboard, touchpad, buttons, speakers, processors, memory, battery and the like, while the upper display unit or assembly can have one or more displays, touch screens, buttons, speakers and so forth. It is often desirable to electrically connect various operational components from the lower base to the upper display assembly, and vice-versa.

Typically, the lower base and upper display components in laptops, clamshell phones and the like are coupled together using a hinge assembly. The hinge assembly allows an upper display component to rotate or pivot relative to a lower base component, which may remain in a desired static position. The display housing is typically movable about the hinge assembly between a closed position against the base housing and an open position with the display, keyboard and other input devices exposed for use. Such hinge assemblies typically have one portion that is secured to the upper display housing and another portion that is secured to the lower base housing. Portable computer hinges typically incorporate spring/friction mechanisms for rotating the display housing and for maintaining it in a static position. With the constant decrease in the size of portable computers and other similar devices, a desire to decrease the size of the hinge assemblies is strong.

Various issues arise when the design of a hinge assembly is decreased, however. For example, a greater outer force can be required to generate a suitable friction force sufficient to maintain the upper display assembly in an open position. This force increase can result in increased stress on the hinge assembly as well as any associated electrical connectors. In this regard, there remains a need to maintain electrical connections between the upper display portion and bottom base portion without unduly jeopardizing the reliability of such wirings or connections. Further, the ability to provide stronger parts and assemblies that perform a hinging function with fewer overall parts would be beneficial from a manufacturing perspective.

While many designs and techniques used to provide hinge mechanisms for portable computing devices have generally worked well in the past, there is always a desire to provide improvements in such hinges, particularly where such improvements can result in a smaller overall hinge design. Therefore, a smaller yet reliable, rugged, and lower force hinge assembly that facilitates the passage of associated electrical connectors while using fewer parts for use in a portable computing device is desired.

SUMMARY

It is an advantage of the present invention to provide hinge assemblies for portable computing devices that are smaller yet still reliable, rugged, and requiring lesser outer forces, and that also facilitate the passage of associated wires while using fewer overall parts. This can be accomplished at least in part through the use of a hinge assembly that includes a hollow and partially annular clutch allowing for wires to pass therethrough, as well as at least one connector that is integrally formed with the hollow and partially annular clutch.

Broadly speaking, the embodiments disclosed herein describe a hinge assembly arranged to pivotally couple a lower base portion of a portable computing device to an upper lid or display portion of the portable computing device. A portable computing device can be a laptop computer or a cellular telephone, for example.

In various embodiments, a hinge assembly arranged to pivotally couple a portable computer base portion to a portable computer lid portion includes an elongated, hollow and partially open clutch, a first fastening component adapted to couple the hollow clutch to the lid portion of the portable computing device, and a second fastening component adapted to couple the hollow clutch to the base portion of the portable computing device. The hollow clutch can be partially cylindrical in nature, and can include a partially annular outer region and a central bore region surrounded by the partially annular outer region. The central bore region can be arranged to permit the passage of and provide support for one or more electrical conductors adapted to electrically connect the base portion to the lid portion of the portable computing device. In addition, at least one of the first and second fastening components can be integrally formed with the hollow and partially annular clutch, which results in stronger and fewer parts overall. The partially annular outer region can have a cross-section that defines a material bearing portion and an open region. In some embodiments, the partially annular outer region can have a thickness that varies across the cross-section of the material bearing portion of the partially annular outer region.

Other apparatuses, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The included drawings are for illustrative purposes and serve only to provide examples of possible structures and arrangements for the disclosed inventive computer hinge having a hollow clutch. These drawings in no way limit any changes in form and detail that may be made to the invention by one skilled in the art without departing from the spirit and scope of the invention.

FIG. 1A illustrates in side elevation view an exemplary portable computing device.

FIG. 1B illustrates in side cross-sectional view an exemplary hinge mechanism from the portable computing device of FIG. 1A

FIG. 2A illustrates in side cross-sectional view an exemplary hinge mechanism having a hollow clutch according to one embodiment of the present invention.

FIG. 2B illustrates in side cross-sectional view the exemplary hollow clutch of FIG. 2A according to one embodiment of the present invention.

FIG. 3 illustrates in partial side cross-sectional view the exemplary hinge mechanism of FIG. 2A as being installed in a portable computing device according to one embodiment of the present invention.

FIG. 4A illustrates in partial top perspective view the integrated hollow clutch and connector of the exemplary hinge mechanism of FIG. 3 as installed but with the wirings removed according to one embodiment of the present invention.

FIG. 4B illustrates in elevated end perspective view the removed exemplary integrated hollow clutch and connector of FIG. 4A with wirings installed according to one embodiment of the present invention.

FIG. 5 illustrates in top perspective view an exemplary hollow clutch and friction band combination according to one embodiment of the present invention.

FIG. 6 illustrates in front perspective view an exemplary alternative hollow and partially annular clutch and friction band combination according to one embodiment of the present invention.

FIG. 7A illustrates in front perspective view the partially annular exterior component of the clutch of FIG. 6 according to one embodiment of the present invention.

FIG. 7B illustrates in side cross-sectional view the partially annular exterior component of FIG. 7A according to one embodiment of the present invention.

FIG. 8 provides a flowchart of an exemplary method of attaching a lid portion to a base portion of a computing device using an integrated hollow clutch and fastener according to one embodiment of the present invention.

DETAILED DESCRIPTION

Exemplary applications of apparatuses and methods according to the present invention are described in this section. These examples are being provided solely to add context and aid in the understanding of the invention. It will thus be apparent to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the present invention. Other applications are possible, such that the following examples should not be taken as limiting.

In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments of the present invention. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the invention, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the invention.

The invention relates in various embodiments to a portable computing device, such as any of various laptop computers manufactured by Apple Inc. of Cupertino, Calif. Although the various embodiments set forth in detail herein are described with respect to laptop computers, it will be readily appreciated that the various embodiments set forth herein can also apply to other forms of computing devices having hinged major components in communication with each other. For example, clamshell type cellular telephones, among other computing and electronic devices, can also utilize the various hinge assemblies, hollow clutches and details of the present invention.

Computing Devices

One example of a portable computing device in the form of a laptop computer is shown in side elevation view in FIG. 1A. As shown, laptop computer 1 can include an upper lid or display portion 10, and a lower base portion 20, which lower base portion can include one or more processors, memories, batteries, power sources, keyboards, buttons, touchpads ports and the like. A hinge mechanism 30 can generally serve to mechanically pivotally couple lid portion 10 to base portion 20.

Continuing with FIG. 1B, an exemplary hinge mechanism from the portable computing device of FIG. 1A is illustrated in side cross-sectional view. Hinge mechanism 30 can include an outer clutch barrel 40, an internal clutch 50, and a collection of wires or other electrical connectors 62, which may be enclosed in an outer cover 60 or otherwise bound together, as will be readily appreciated. Such electrical connectors generally serve to provide power and communications between devices in the lid and base portions of a portable computing device, such as power and data from the base unit to a display device in the lid unit. Communications from an antenna in the lid portion to a processor in the base portion is another example of a use for one of electrical connectors 62.

As shown, the grouping of electrical connectors 60 typically shifts from a first position A to a second position B when the lid portion and base portion of the portable computing device are moved or pivoted with respect to each other. Although such a movement in the grouping of wires or electrical connectors 60 is generally well known, such movements are generally disadvantageous in that continued movements can cause wear and tear to the wirings 62, or eventual blockage, increased friction or other undue inconvenience with respect to the pivoting hinge mechanism itself as a result of long term extend use.

Hollow and Fully Annular Clutch

Turning next to FIG. 2A, an exemplary hinge mechanism having a hollow clutch according to one embodiment of the present invention is similarly shown in side cross-sectional view. Similar to above hinge mechanism 30, inventive hinge mechanism 100 can include an outer clutch barrel 140 as well as an internal clutch 150. Unlike the foregoing hinge mechanism, however, the internal clutch 150 of hinge mechanism 100 is hollow, and allows for the passage of a cluster or collection 160 of electrical conductors 162 through a cavity 152 therethrough. In some embodiments, such an internal hollow clutch 150 can be cylindrical in nature, and can have an annular outer region and a central bore region surrounded by the annular outer region. Again, the central bore region is adapted to permit the passage of and provide support for one or more electrical conductors adapted to electrically connect a base portion to a lid portion of a portable computing device.

The various advantages for such a hollow clutch component are numerous. The annular clutch can be stiffer and lighter with a larger diameter, since the need for space for electrical conductors outside the clutch is eliminated. In one example, the radius of a cylindrical clutch can be increased from 4.0 to 4.8 millimeters without changing the size of the clutch barrel, due to the electrical conductors being relocated to inside the hollow clutch. A mechanical stop put on the outside of the larger diameter clutch then has a lower moment to apply force, which requires less force to stop the clutch during rotation, as will be readily appreciated. A larger diameter clutch also results in more surface area to help stop movement using a friction band, as will also be readily appreciated. In addition, rather than the electrical wires or cables being moved back and forth between to points, such as points A and B above, rotation of the lid and base components only results in slight twisting of the electrical connectors, which eliminates or substantially reduces wear and tear problems in that regard. In one example, the hollow clutch material can be steel, although a variety of different materials can be used, as will be readily appreciated.

Continuing with FIG. 2B, the exemplary hollow clutch of FIG. 2A is illustrated in side cross-sectional view according to one embodiment of the present invention. Clutch 150 can be formed of any suitable material such as stainless or alloy steel having outside radius R₁ having an exterior surface area S_(A) per unit length defined as equation 1 as: S_(A)=2πR₁.  Eq (1) Clutch 150 can include interior region 152 having inside radius R defining interior volume S_(VOL) per unit length as defined as equation (2): S_(VOL)=πR².  Eq (2)

In the described embodiment, inside radius R can vary to provide sufficient space to accommodate cable bundle 160. As noted above, cable bundle 160 can include a plurality of electrical connectors, wires or cables arranged to electrically connect electrical components in an upper lid portion, such as a display assembly, and base portion or unit pivotably connected to each other by way of clutch 150. In this way, both power and data can be passed between the display assembly and base unit.

Isolating cable bundle 160 within the interior volume 152 of clutch 150 helps to reduce cable sliding and reduces the probability of cables snagging. In this way, the reduced snagging provides for greater long term reliability. Moreover, the shape integrity of cable bundle 160 is improved as is the ability to prove out a design is improved since it is no longer necessary to require an entire system to demonstrate that the cables within cable bundle 160 work according to specification. In order to provide restraining force F_(res) sufficient to maintain the display assembly in the open position relative to the base unit, a friction band 170 can be placed in direct contact with the exterior surface S_(A) of clutch 150 at an outer friction surface. Therefore, restraining force F_(res) per unit length can be directly related to outside radius R₁

Therefore, in addition to providing a secure inner repository for cable bundle 160, due to the increase in outside radius, the friction force created can be also be increased due at least in part to the increase in outer surface area, as well as the increase in moment arm due to the greater value of the outside radius R1. In this way, hollow clutch 150 can be stiffer and lighter. Moreover, an end stop 154 can be placed on an outside surface S_(A) of the clutch 150. Due to the larger radius R1 of the clutch, a lower moment is required to be applied to generate a given force to stop movement of the display or upper assembly, such as by a corresponding stop (not shown) outside the hollow clutch that acts against clutch end stop 154 where the amount of rotation between lid and base portions is desired to end, as will be readily understood.

Moving next to FIG. 3, the exemplary hinge mechanism of FIG. 2A is depicted in partial side cross-sectional view as being installed in a portable computing device according to one embodiment of the present invention. Portable computing device 200 can be, for example, a laptop computer having an upper or lid portion 210 and a lower or base portion 220, only portions of which are shown here for purposes of illustration and focus. A hinge mechanism used to pivotally couple the lid and base portions can include a clutch barrel 240, a hollow clutch 250 and at least one fastening component 280, which can be used to couple the hollow clutch to the base portion 220 of the portable computing device 200. A plurality of cables or electrical connectors 260 can pass through the hollow portion of clutch 250, and travel to respective connections at the base portion 220 out of one end of the hollow portion, and also travel to respective connections at the lid portion 210 (not shown) out of the other end of the hollow portion.

Fastening component 280 can include a portion 282 that surrounds all or part of the outer circumference of hollow clutch 250 at at least one location, and also another portion 284 having one or more holes 286 therethrough to allow for fastening to the base portion 220 of the portable computing device. One or more fasteners 290 can be used through the one or more holes 286 in fastening component 280 to fasten the base portion 220 to the hollow clutch 250. Such fasteners 290 can be, for example, screws, bolts, nails, pins, rivets or any other suitable fastening device, as will be readily appreciated by those skilled in the art.

Continuing with FIG. 4A, the integrated hollow clutch and connector of the exemplary hinge mechanism of FIG. 3 as shown as installed again, but with the wirings removed and in partial top perspective view. Again, portable computing device 200 can include a base portion 220 (partially shown in cutaway view) that is pivotally coupled to a top or lid portion (not shown) by way of a hinge mechanism having a hollow clutch 250. This hollow clutch 250 can have a first region 256 having an annular outer component and a central bore component surrounded by the annular outer component, wherein the central bore component is adapted to permit the passage of and provide support for one or more electrical conductors adapted to electrically connect the base and lid portions, as described above. Such a first region 256 can be cylindrical, for example.

In addition, the hollow clutch 250 can also include a second region 258 having a fastening component adapted to couple the hollow clutch to the lid portion or the base portion of the portable computing device. Such a second region 258 can be flat and have one or more holes 259 through it, for example. Preferably, the first hollow region 256 and the second region having a fastening component 258 are integrally formed as a single part, which again can be formed of any suitable material, such as stainless or alloy steel. The one or more holes 259 are adapted to permit one or more fasteners (not shown) to pass therethrough, which then results in the fastening of the hollow clutch and connector 250 to the lid portion of the computing device.

Similar to the foregoing, such fasteners can be, for example, screws, bolts, nails, pins, rivets or any other suitable fastening device, as will be readily appreciated by those skilled in the art. Also, it will be readily appreciated that although the exemplary embodiments of FIGS. 3 and 4A show separate fastening component 280 as coupling the clutch portion 256 to the base portion 220 and the integrated fastening component 258 as coupling the clutch portion to the lid portion 210 of the portable computing device, such an arrangement can be readily reversed. That is, the integrated clutch and fastening component 250 can instead be directly fastened to the base portion, while the separate fastening component 280 can couple the hollow clutch portion 256 to the lid portion of the computing device.

FIG. 4B illustrates in elevated end perspective view the removed exemplary integrated hollow clutch and connector of FIG. 4A with wirings installed according to one embodiment of the present invention. As seen from this different perspective, integrated hollow clutch and fastening component 250 again includes a hollow and cylindrical first region 256 that supports and allows various cables or electrical connectors 260 to pass therethrough, as well as a fastening component second region 258 having one or more holes 259 therethrough. Again, this second region 258 is adapted to facilitate the direct fastening of the hollow clutch to one of a lid or base portion of an associated computing device. Also shown is the separate fastening component 280 that couples the integrated hollow clutch and fastening component 250 to the other of the lid and base portions.

Continuing with FIG. 5, an exemplary hollow clutch and friction band combination according to one embodiment of the present invention is illustrated in top perspective view. Hollow clutch and friction band combination 201 can be identical or substantially similar in many or all regards to that which is shown in FIGS. 4A and 4B. In particular, integrated hollow clutch and connector 250 can include a first region or shaft 256 having an internal cavity 252 and a second region or integrated mount 258 having one or more holes 259. An integrated stop 254 can also be formed on an outer surface of the shaft portion 256.

In addition, an integrated friction band and fastening component 270 can serve both to provide friction against shaft 256 during component rotation, and also to fasten or mount the friction band to the respective base or lid portion of the computing device. In such an arrangement where the friction band doubles as a mount or fastening component, then friction band 270 effectively serves as the fastening component 280 above. As such, integrated mount portion 278 is the equivalent of portion 284 above, while holes 286 and 279 are effectively the same. Also, an integrated stop 274 on friction band and integrated mount 270 can be strategically formed and positioned to interact with opposing integrated stop 254 on hollow clutch and connector 250, such that relative rotation between these parts is stopped at a particular angle or location.

Numerous advantages arise through the use of such an integrated hollow clutch and fastening component as a single part. Again, the hollow clutch portion can be stiffer and lighter with a larger diameter, since the need for space for electrical conductors outside the clutch is eliminated. A mechanical stop put on the outside of the larger diameter clutch then has a lower moment to apply force, which requires less force to stop the clutch during rotation, such that the mechanical stop can be smaller yet stronger and more reliable. A larger diameter clutch also results in more surface area to help stop movement using a friction band, as will also be readily appreciated. Reduction in movement to the cables or electrical connectors is also an advantage. Furthermore, the integration of at least one fastening component with the hollow clutch component, such as components 256 and 258 in single part 250, results in a lower part count, smaller part size and greater strength for the overall hinge mechanism, all of which result in greater ease in manufacturing.

Even further advantages can be realized through the use of such a hollow clutch design. For example, in addition to the cables or electrical connectors, the hollow clutch can also readily facilitate the use of a thermal conduit or heat exchanger running therethrough. Such a heat exchanging component can be adapted to sink heat at one or more locations at the base portion, and conduct this heat through the hollow clutch and into the upper or lid portion, where the heat can then be dispersed. In the event that heat in the lid portion is the greater problem, then the reverse can be true for such a thermal conduit through the hollow clutch.

Yet another application for the hollow portion of the clutch can be as a reservoir for grease, oil or any other suitable lubricant. As will be readily appreciated, it may be desirable to facilitate the lubrication of various frictionally contacting parts within the hinge mechanism. To the extent that an ongoing ready supply of lubricant can be located within the hinge mechanism itself, a suitable design can increase the lifespan of such frictionally contacting parts, or at least extend the lengths of time that are required between parts servicing. Such a lubricant can be contained within the hollow clutch region, with one or more caps, seals and/or strategically places and sized openings, such that a desired amount of grease, oil or other suitable lubricant is made available as it may be desirable for part lubrication.

Formation of friction band and fastening component 270 can be facilitated a number of ways. For example, sheet metal bands can generally be wrapped around a hollow shaft in one embodiment. As another possibility, a plurality of metal sheets can be stamped in certain patterns, with the resulting stamped portions then being stacked and combined together to form the finished component. Sheet metal having a thickness of about 0.4 mm, for example, can be used for this purpose. As a particular non-limiting example, the thicknesses of integrated mount portion 278, integrated stop 274 and the entire annular portion of component 270 can be about 1.0 mm, although other dimensions are also certainly possible.

Advantages of these techniques can include part tolerances that are well held, and also utilizing straightforward processes using standard off the shelf materials. In using these types of formation techniques, however, the hollow annular outer shaft portion of component 270 tends to be closed off, and the outer wall thickness is typically constant and symmetric in nature. This can result in limits as to where the hollow clutch can be located, as well as requirements to add material where needed for greater part strengths, such as to facilitate attachment to other parts or items. Weakness or failure in integrated stop 274 can also arise if the sheet metal used to form the component is too thin.

Hollow and Partially Annular Clutch

Turning now to FIG. 6, an exemplary alternative hollow and partially annular clutch and friction band combination according to one embodiment of the present invention is illustrated in front perspective view. Hollow and partially annular clutch 300 can be similar in many regards to hollow clutch and friction band combination 201 illustrated in FIG. 5. In particular, integrated hollow clutch and connector 350 can include a first component or shaft 356 having an internal cavity and a second component or integrated mount having one or more holes. An integrated stop can also be formed on an outer surface of the shaft portion (not shown).

Partially annular exterior component 370 can be similar in function to friction band and fastening component 270 from the above embodiment, albeit with several significant differences. Similar to the foregoing embodiments, partially annular exterior component 370 can include an exterior portion that substantially surrounds shaft 356 of hollow clutch 350, as well as an integrated mount portion 378 that can be flat and include one or more holes 379 for mounting therethrough. Also, an integrated stop 374 can be strategically formed and positioned to interact with the opposing integrated stop on hollow clutch 350, such that relative rotation between these parts is stopped at a particular angle or location.

Unlike the foregoing embodiments, however, partially annular exterior component 370 can have a significant gap 390 around the outer circumference of its partially annular and elongated portion. Gap 390 can be positioned opposite mount portion 378, such that the overall clutch 300 can be advantageously positioned closer to an internal wall or other tight region within the overall computing device. Further, the wall thickness of the partially annular outer component surrounding shaft 356 can be asymmetric, such that more material is provided where greater strengths are needed along the various portions of component 370. For example, the amount of material for integrated stop 374 can be increased simply by way of increasing the thickness of the partially annular exterior component 370 itself at the integrated stop location. As noted above, such an increase in part material thickness is ordinarily difficult where this component is formed using a wrapped or stamped sheet metal formation process.

Continuing with FIGS. 7A and 7B, the partially annular exterior component of the clutch of FIG. 6 is illustrated in front perspective and side cross-sectional views respectively. Again, partially annular exterior component 370 can include a partially open cylindrical region or internal cavity 352 that is designed to accommodate the shaft of the hollow clutch therewithin. The partially annular or partially open cylindrical aspect is due to the presence of gap 390 that breaks up the continuity of this outer annular component at one location, preferably opposite or offset from integrated mount portion 378. In effect, the partially annular outer region of component 370 has a cross-section that defines material bearing portions 391, 392 and an open region 390.

As can be seen in FIG. 7B, the thickness of the partially annular region of component 370 can vary, from nothing at gap 390, to thin at region 391 near the gap, to thick at region 392 near the integrated mount portion 378. Variances in thickness along this partially annular region can be specifically designed as desired to account for any issue or feature where added strength or more space may be desired. For example, where less strength is needed and more space is desirable, such as at region 391, then the material thickness can be deliberately thin. Conversely, where greater strength is needed and space is not as much of an issue, such as at integrated stop 374 or where the annular portion integrates with mount portion 378 at region 392, then the material can be deliberately thicker. Other thicknesses and features may also be built in to the varying thickness across the partially annular portion, as may be desired.

Integrated mount portion 378 can be flat, relatively thick, and can include a number of holes 379 therethrough to facilitate mounting of the clutch 300 to another device component, such as an outer housing for a base or lid of a laptop computer, for example. Integrated stop 374 can be formed at a thicker region of partially annular exterior component 370, such that greater strengths and less failure can be observed by this item. In addition, the thickness of integrated mount portion 378 can be increased, such that this portion of component 370 has greater strength and stability where it is mounted to the rest of the overall device. Further, although only two holes 379 through integrated mount portion 378 are shown, it will be readily appreciated that more or fewer holes may also be used.

Formation of partially annular exterior component 370 can be facilitated a number of ways. For example, a cold drawing extrusion process can be used to draw material longitudinally according to the specific cross-section desired. As another possibility, casting or metal injection molding can be used to form component 370. Under either of these formation approaches, secondary machining or finishing steps may be used to form the final component, particularly where the internal diameter of the partially annular region must be very precise. As a particular non-limiting example, the thicknesses of integrated mount portion 378, integrated stop 374 and region 392 can be about 1.5 mm, while the thickness of region 391 can be about one-third of that of the thicker regions (i.e., 0.5 mm), although other dimensions are also certainly possible.

Various advantages can be realized by way of forming and using such a partially annular exterior region having an asymmetrical thickness. For example, the need to add extra material to a sheet metal formed cylindrical region to facilitate attachment to other parts can be eliminated. In addition, an asymmetric thickness distribution of wall section allows for an opening or gap 390 and thin region 391, which allows the overall clutch to be positioned closer to an internal wall of the overall device. The asymmetric wall thicknesses also provides more thickness and thus strength where it is particularly needed, such as at the integrated stop 374 and near the integrated mount portion 378. Still further, an asymmetric wall thickness distribution results in operational pressures and frictional forces that are more evenly distributed across the entire internal surface of the partially annular region against the shaft contained therein, which more evenly distributes wear and increases longevity of the respective components.

Methods

Lastly, FIG. 8 provides a flowchart of an exemplary method of attaching a lid portion to a base portion of a computing device using an integrated hollow clutch and fastener according to one embodiment of the present invention. It will be understood that the provided steps are shown only for purposes of illustration, and that many other or different steps may be included in the process, as may be desired. Furthermore, the order of steps may be changed where appropriate and not all steps need be performed in various instances. For example, steps such as steps 404 and 406 may be reversed, while step 412 may be at least partially performed at any point in the process. Other differences may also be possible, and it will be readily appreciated that the described steps and order are not limiting in any way.

After a start step 400, an initial process step 402 involves selecting a lid portion and a base portion to be coupled together to form a single computing device, such as a laptop computer, for example. At subsequent process step 404, a single part integrated hollow clutch and fastening component is fastened to the lid portion. Again, the integrated clutch and fastening component could alternatively be fastened to the base portion instead, such as where a separate fastening component is to be fastened to the lid portion instead, as noted above.

At the next process step 406, a separate fastening component is slid over or otherwise coupled to the outer surface of the hollow clutch component, after which the separate fastener is fastened to the base or bottom portion of the computing device at step 408. At step 410, one or more cables or electrical connectors are fed through the hollow clutch portion, with one end of the connectors intended for the lid portion and the other end of the connectors intended for the base portion. At following process step 412, the cables or electrical connectors are then connected to their respective connections at the base and lid portions of the computing device. At the least, such connections are preferably completed at step 412, such as where initial connections may be made earlier in the process, after which the method then ends at end step 414.

Although the foregoing invention has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described invention may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the invention. Certain changes and modifications may be practiced, and it is understood that the invention is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims. 

What is claimed is:
 1. A portable computing device, comprising: a base portion; a lid portion comprising a display electrically coupled with one or more of a plurality of electrical components disposed within the base portion by one or more electrical conductors; and a hinge assembly that pivotally couples the base portion to the lid portion, the hinge assembly comprising: a clutch assembly, comprising: an outer component having a varying cross-sectional thickness that defines a hollow and partially open material bearing portion, a first stop unitarily formed with the outer component, a thickness of the first stop varying with the varying cross-sectional thickness of the outer component, a shaft having a portion of which is disposed within the bearing portion such that some of an outer surface of the shaft is free of the outer component, the shaft configured to permit the passage of and provide support for the one or more electrical conductors, and a second stop unitarily formed with the shaft that interacts with the first stop to prevent rotation of the lid portion past a particular angle of rotation with respect to the base portion.
 2. The portable computing device of claim 1, wherein the portable computing device is a laptop computer.
 3. The portable computing device of claim 1, wherein the varying cross-sectional thickness of the first stop is the same as at least a portion of the varying cross-sectional thickness of the outer component from which the first stop extends.
 4. The portable computing device of claim 1, wherein the varying cross-sectional thickness of the outer component varies asymmetrically.
 5. The portable computing device of claim 1, wherein the varying cross-sectional thickness of the outer component varies from a maximum thickness to a minimum thickness that is about one-third of the maximum thickness.
 6. The portable computing device of claim 1, further comprising: a first fastening component adapted to couple the outer component to the base portion, and a second fastening component adapted to couple the shaft to the lid portion, wherein at least one of the first fastening component and the second fastening component is integrally formed with the outer component or shaft as a single part, wherein the integrally formed fastening component includes a flattened surface having one or more holes extending therethrough, the one or more holes accepting one or more fasteners that fasten the integrally formed fastening component to the lid portion or the base portion of the portable computing device.
 7. A method for attaching a lid portion to a base portion of a computing device, the method comprising: fastening a clutch assembly to one of the lid portion or the base portion of the computing device, wherein said clutch assembly includes an outer component, a hollow shaft at least a portion of which is internal to the outer component, wherein the outer component has a varying cross-sectional thickness that defines a hollow and partially open material bearing portion; forming at least some of an outer surface of the hollow shaft to remain free of the outer component; and unitarily forming a first stop with the outer component that cooperates with a second stop unitarily formed with the hollow shaft, the first stop having a thickness substantially the same as the varying cross-sectional thickness of the outer component and being configured to cooperate with the second stop to define an end to a rotation between the lid portion and the base portion.
 8. The method of claim 7, further including the steps of: feeding one or more electrical connectors through the hollow shaft of the clutch assembly; and electrically coupling the one or more electrical connectors to respective connections at both of the lid portion and the base portion of the computing device.
 9. The method of claim 7, wherein the computing device is a laptop computer.
 10. A hinge assembly suitable for use in a portable computing device having a first body portion and a second body portion, the hinge assembly comprising: a clutch assembly configured to pivotally couple the first body portion to the second body portion, the clutch assembly comprising: an outer component having a varying cross-sectional thickness that defines a hollow and partially open material bearing portion, the outer component configured to be coupled to the first body portion, a first stop unitarily formed with the outer component, a thickness of the first stop varying in accordance with a portion of the outer component from which the first stop extends, a shaft configured to be coupled to the second body portion, the shaft comprising: a cylindrical portion disposed within the material bearing portion, a channel disposed along a longitudinal axis of the cylindrical portion and configured to support one or more electrical conductors, and a second stop unitarily formed with the shaft and configured to cooperate with the first stop to limit rotation of the cylindrical portion with respect to the material bearing portion.
 11. The hinge assembly of claim 10, wherein the outer component includes a portion having a substantially C-shaped cross section.
 12. The hinge assembly of claim 10, wherein the varying cross-sectional thickness of the outer component varies from a maximum thickness to a minimum thickness that is about one third of the maximum thickness.
 13. The hinge assembly of claim 10, wherein the channel is disposed between a first opening and a second opening of the cylindrical portion, the first and second openings disposed at opposite ends of the cylindrical portion.
 14. The hinge assembly of claim 10, further comprising a fastening component integrally formed with the shaft and configured to be coupled to the second body portion.
 15. The hinge assembly of claim 10, wherein the varying cross-sectional thickness of the outer component varies asymmetrically.
 16. The hinge assembly of claim 10, wherein the outer component further comprises a fastening component configured to be coupled to the first body portion. 